International Journal of Science, Engineering and TechnologyAuthors: Sankalp Sonkusare, Dr. Ritesh Sambare
Abstract: Lithium-ion batteries generate heat during charge and discharge, and their performance, ageing and safety depend on temperature and temperature uniformity. This review synthesizes foundational and recent literature on battery thermal management systems (BTMS), with emphasis on indirect liquid cooling, serpentine and microchannel passages, and evaporative mist cooling. The literature shows that cooling performance depends on the battery heat load, cell-to-coolant thermal contact, channel geometry, coolant conditions, heat-exchanger capacity and auxiliary power. Serpentine channels can improve heat transfer coverage, but their hydraulic resistance and pumping demand must be considered alongside peak temperature and cell-to-cell temperature spread. Mist cooling can add evaporative heat rejection, while its outcome depends on humidity, airflow, droplet evaporation and water carry-over. Findings from the two papers central to this project—a 2024 mist-cooling study and a 2026 serpentine microchannel experiment—are therefore interpreted within their own test boundaries rather than treated as direct performance forecasts. The review applies this synthesis to a proposed laboratory system using a copper serpentine-tube liquid loop and optional mist introduced at the radiator air inlet. Since assembly and testing are pending, the manuscript reports no experimental result for that system. It recommends matched test cases and combined thermal, hydraulic and electrical measurements to establish whether additional cooling justifies pump, fan and mist-system energy use.
DOI: https://doi.org/10.5281/zenodo.23594498
